FACC starts series production of composites for Rolls-Royce Trent engine

With full-rate production in 2017, FACC will deliver four shipments/week of composite fan track liners, rear case liners, bifurcation linings and anti-fluid panels used on Airbus A350 XWB powerplants.

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FACC (Ried im Innrkreis) is responsible for development and production of the engine composites as part of a life-of-program contract for the new Trent XWB engine – a fuel efficient power system that entered service at the end of 2014, following delivery of the first Airbus A350 XWB to launch customer Qatar Airways.

Rolls-Royce (London, UK) awarded the contract to FACC in 2012. According to the current state of the engine orders, it envisages a total order volume of approximately 300 million US$ and deliveries at least up to the year 2028. The start of series production of the Trent XWB engine composite components marks the successful conclusion of many years of research and development by FACC.

"The schedule for this project was challenging. The timely start of series production of the engine components for the Trent XWB powerplant is a major step by FACC of demonstrating its commitment to adding value to the program,” said Walter Stephan, Chief Executive Officer of FACC. “It is now time to make every effort to ensure component deliveries at the steadily increasing production rates.” Once the program reaches full rate production in 2017, FACC will support the Trent XWB assembly line by delivering four shipments of engine composites per week.

Engine composites: lighter, quieter, yet still high strength
The engine composites order package from Rolls-Royce contains four different engine components:

The fan track liners are linings in the fan casings. They form a contact seal with the engine blades, preventing turbulence and thereby significantly influencing engine performance. They also absorb impact energy from hailstones and chunks of ice. Furthermore, the high-strength carbon fiber parts play an important role in containing damage in the event of theoretical blade failure.

The rear case liners are sound-absorbing acoustic panels lining the engine which enable compliance with strict regulatory noise emission limits. Use of composite technology contributes to achieving effective noise insulation with only minimal additional weight and unvaryingly high strength.

FACC also manufactures bifurcation fairings and anti-fluid panels. With their special properties and thanks to specific manufacturing technologies, the FACC engine composites set standards in terms of weight, acoustics, and aerodynamics, thereby making an important contribution to higher efficiency and better environmental compatibility of the new Trent XWB engine family.

15 years of Rolls-Royce – FACC collaboration
"The assemblies developed in close cooperation with the customer, coupled with an increased proportion of composite components in the overall weight of the new Trent XWB compared with conventional engines, represent a substantial basis for further expansion of the business relationship between FACC and Rolls-Royce," says VP of FACC engines & nacelles division Robert Braunsberger. Indeed, this year the two companies celebrate 15 years of partnership in the development and production of engine composites.